International Research Journal of Engineering and Technology (IRJET)
e-ISSN: 2395-0056
Volume: 06 Issue: 03 | Mar 2019
p-ISSN: 2395-0072
www.irjet.net
Study and Analysis of Time Factor in the Utilization Process
Sriram S1, Gokul R2, Pradeep A D3, Sakthivel Murugan E4
1,2Student,
Mechanical Engineering, BIT sathyamangalam, Tamil Nadu
Mechanical Engineering, BIT sathyamangalam, Tamil Nadu
---------------------------------------------------------------------***---------------------------------------------------------------------3,4Asst.Professor,
The main market driver globally are Oil and Gas
Industries where there is a huge demand for Gear
Manufacturers. Because of the innovative advances, the
reception of robots and modern computerization is picking
up unmistakable quality. Computerization and robots are
generally embraced in every single mechanical part,
principally in fast and tedious undertakings. Finally, complete
content and organizational editing before formatting.
Abstract - Manufacturing Engineering evolves under the
category of time, precision, rate of production and most
importantly costs over the different era of the history. The
terms that are engaged can be collect, interpolate, and
analyses for the deep knowledge of actual working of the
specific process if any interests. Although the collection of
information is not easy as it sounds and it requires keen
observations and in-depth process view. As the process
continues with interpolation cycle. They in turn needs accurate
and reliable past record data’s for precise tracking of
processed information in real. With correct information in
your hands through above two process, we can assure that the
obtained statistical figures can be reliable and also decisions
can be made with respect to figures. In general, collection of
correct information is challenging work which has several
different techniques and procedures to go for, and selection of
apt technique with company’s structure and policy, made us
stood aside from others.
1.2 OBJECTIVE
The objective of this study is to track actual time for
production of products irrespective of time that datasheets
tell. It also focus on techniques to undergo, resources,
strategies to collect the required information. This study
helps the organisation to identify and eliminate the nonvalue adding process form their procedure and addition of
value-adding process for effective usage of resource and
time. As efficiency of the particular process hikes, if all the
above mentioned steps were taken into account. There is no
place for false data inside the data pool, once the system is
adopted to modern upgrades.
Key Words: Hob travel time calculation, Tool touch time,
Data interpolation, statistical analysis, Time factor,
Increase utilization
2. Methodology
1. Introduction
It explains about the various steps and procedure to be
accomplished for successive application of data under the
guidance of data processing technique. It also describes about
the various terms and condition for the introduction of new
term or parameter to the operating system for enhancement
of system efficiency. Shewale et al [1] discussed about the hob
tool efficiency on basis of their statement the dimensions
noted from the hob are revaluated after the particular period
of time.
Today, all the manufacturing companies share a common
motto of satisfying their customers by delivering right
product at right time with right quality. While companies
were concentrating on these factors, many constraints will
come to the account of manufacturer when they look into the
manufacturing process. Those constraints also contain non
value adding elements which has to be eliminated for
efficient operation of the industry. The report is organized as
follows by covering about brief explanation about factors in
gear manufacturing, selection criteria of the data, way to
collect the data and to track the actual tooth touch time,
overall time consumed for the process.
2.1. Data Processing Technique:
In this data processing technique, various processes and
steps to achieve effective data are discussed below. These
steps has to be followed to get an accurate and reliable data
which can be used to calculate precise calculation over the
tool touch time.
1.1 PROBLEM STATEMENT
Gear manufacturing industry is one of the crucial and a most
important sector among all industrial product manufacturing
industries. As gears plays a major role in industrial sectors
like Cement industries, Steel industries even they are also
been used in various defense organizations where
dimensional precisions plays a major role.
© 2019, IRJET
|
Impact Factor value: 7.211
The most general and basic structure was described in figure
2.1.
|
ISO 9001:2008 Certified Journal
|
Page 75
International Research Journal of Engineering and Technology (IRJET)
e-ISSN: 2395-0056
Volume: 06 Issue: 03 | Mar 2019
p-ISSN: 2395-0072
www.irjet.net
Formula used for time calculation
Comparison of speeds between successive
months
Comparison of speeds between jobs
b) Time section
Time section consists of data related to time respect to job,
specification, customer, etc. They can be modified as per
comfort of company’s structure without lack of information.
The categorization and framework for this section will be
done by managers, as they are responsible for decisionmaking and thus, this section also plays major role in
management perspective too.
c) Overhead section
Fig 2.1 Steps in Data processing
The section acts as a hub for many parameters which are
inter-related and collected under single cottage. As our
manufacturing minds greatly focused on time, this section
compel all time affecting data other than in time section. The
reason for proposal of this section is “track time affecting
parameters due to unexpected and unavoidable
circumstances “is held. Some of the parameters can be
listed as
This diagram indicates the basic working levels in the
technique. First, we collect information about product like
customer, specifications, model no, drawing no, etc. The
information can be aggregated or obtained from trusted
source like data receiver, data storage unit or may also from
Department managers, Process head officer, Employees
which has lot more possibilities of error or foul play. Once
the way of collecting information is decided, then the next
step is to be categorization or interpolate them with
required parameter figures, etc. As the second part over, the
final is to compare the data with previously collected data
for ensuring that there is a steep of increase curve over
period of time. Also, the changes made in the system have
some payback which has to be viewed in the positive
manner. So ultimately, the purpose of implementation of
technique to system, is to achieve details of positive and real
numbers that are in the play rather than expected or false
numbers that are not actually exists.
Job change time
Job setting time
Machine Idle time
Planned breakdown , etc
ii.
Here, the collected data which is in huge amount will be
segregated into small groups by eliminating unnecessary
data. As the company has prior vision over focused areas,
they collect data and information related to that particular
areas. So overall quantity of data will be reduced and can be
processed much faster and accurately.
2.2. Data collection – Standard Method
The standard procedure of collecting data differs from
company to company. In general, it has some basics sections
which has to be fulfilled by any company who is keen on
their data value. The main scope of this method is to provide
information about the actual time taken for the process.
Some of the key terms are as follows,
i.
For instance, a company can foresee
Monthly production volumes
Total number of products produced over
month periods
Time taken for standard products in
different time periods.
Collection of data
By having precise and actual value in hands, helps firms and
high profile workers greatly to pursue any decisions or make
any change. It is very important to cross-check the
interpolation more than once, for any foul play in the firm
that may affect firm dramatically.
a) Cutting speed section
The cutting speed section comprises details of running
machine like speed of rotation (RPM), feed (f), etc. The
section may also contain extra information like no of starts,
etc in some special cases.
iii.
This information and data collected will be helpful in
© 2019, IRJET
|
Impact Factor value: 7.211
Interpolation of data
Analysis of data
The obtained information through above sections will be
validated and put through analysis for the detailed study and
|
ISO 9001:2008 Certified Journal
|
Page 76
International Research Journal of Engineering and Technology (IRJET)
e-ISSN: 2395-0056
Volume: 06 Issue: 03 | Mar 2019
p-ISSN: 2395-0072
www.irjet.net
knowledge. Generally, the analysis can be carried out for
different scenario depend upon company’s focus areas. This
helps company and its managers to know
appliance. In other dimension, values provide by CNC is
based on technology and make of the machine itself. As the
technology and measuring systems get upgraded, the values
can be more reliable and used without any doubts. It
represent the movement of the tool as it also calculate the
clearance value of height for the tool. Also approach has its
value to contribute to the minimization of utilization of the
process.
What to focus on?
Where to focus?
Where does extra supervision is needed?
Which parameter limits the profit scale?
In detail, analysis shows visual and reliable results which can
be useful in case of decisions made for the upcoming future.
As if any change error in analysis will cause catastrophic
effect on company in the future. So managers visualize the
reports more often and made any alteration if necessary to
run the process smoothly.
The formula for calculation of approach is given as,
a) Helical gear :
[3]
2.3 Data collection – Advanced Method
In order to eliminate any discrepancy in the quality of data
collection, several theories and fundamentals can added to
the system to make them more vulnerable to them. Since the
introduction of this concepts is optional as they require extra
time and manpower to implement into the system. Once it is
introduced to the system, they can operate and regulate with
less manpower and time. One of the fundamentals, we are
going to see is mostly opt for manufacturing industry and
also be used for other industries too but with little
modification.
Where,
W= Depth of cut (inch)
D = Hob outside diameter
G = Gear outside diameter
H = Gear helix angle
b) Spur gear :
Since helix angle for spur gear is either 0 or 1, equation is
simplified as
In our discussion, we are basically following “time” as our
focus area since it plays most crucial role, particularly in
manufacturing industry. So here, there are some additional
information we require to make data, more accurate and
precise.
[3]
ii.
Some of them include
Over-run
Hob overrun is the linear hob travel beyond full cutting
depth required to complete generation of the gear teeth. It
plays important role in precision of teeth depth and
alignment. In general, over run can be automatically
measured by digital measuring system in CNC machines. But
in other cases, the formula used for calculation is
Approach
Over run
Face width
Hob travel
Ultimately from which we can calculate,
Theoretical time taken
Actual time taken
i.
[3]
Approach
Where,
S = addendum of gear in inches
H = Gear helix angle
SA = hob head swivel angle
PA = gear pressure angle
Hob approach is the distance from the point of initial contact
between hob and gear blank to the point where the hob
reaches full depth of cut. The approach length is a function of
hob diameter, gear outside diameter, depth of cut and gear
helix angle.
iii.
In general, approach can be calculated either by manual
using formulae or by CNC machine itself. The manual method
require greater knowledge in both field of work and practical
© 2019, IRJET
|
Impact Factor value: 7.211
Face width
The face width of a gear is the length of teeth in an axial
plane as in case of double helical, it does not include the gap.
|
ISO 9001:2008 Certified Journal
|
Page 77
International Research Journal of Engineering and Technology (IRJET)
e-ISSN: 2395-0056
Volume: 06 Issue: 03 | Mar 2019
p-ISSN: 2395-0072
www.irjet.net
When the face width is too small, the gear has poor capacity
to absorb the shock loads and vibrations.
Table 2.3 Factors and their units
In practice, the optimum range of the face width is in
between 8 and 10 modules. The face width can also be
obtained from CNC along with approach, over run, etc.
The dimension of face width of gear is an important aspect in
the design of gears. If the face width is too large, there is a
possibility of concentration of load at one end of the gear
tooth.
iv.
vi.
Hob travel
Description
Number of teeth
Hob travel
Cutter speed
f
i
Feed
Number of starts
in hob cutter
Units
Inch
Revolution per
minute (RPM)
Inch / RPM
-
Actual time calculation
The actual time calculation is the actual time during which a
process occurs or complete. It is always lower than the
calculated theoretical time due to many error/reasons. By
comparing the both time values, deviance occurred can be
classified and categorized into groups that can be minimized
or eliminated in the upcoming cycles. The actual time
calculation is carried out by using formula
The hob travel length consists of three elements,
Gear face width
Hob approach
Hob over run
The gear face width is also indicated on the part print as the
width of the gear blank. When more than one part is loaded
per cycle, the total gear width must be taken into account.
Hob travel provides information about movement of job and
cutter which is very useful in terms of calculation of actual
time of the job.
v.
Factors
Z
L
N
[3]
The difference between two formulas other than their
names is
Theoretical time calculation
The theoretical time is the time taken by the process found
by using formula and theorems. But in general, theoretical
time cannot be achieved as there is always error in every
process which make the output lower than theoretical value.
In our case, theoretical time can be calculated using formula
In theoretical time formula, speed and feed rate will
be the assigned values for the process by either
machine suppliers or R&D engineers.
In actual time formula, speed and feed rate will be
the values entered by operators at the time of
process
In both formula, factors like “Z, i” are constant as
denote standard job and cutter values.
Also, factor “L” will be varying for every jobs.
[3]
3. Result Comparison
By substituting all the factor value required in the formula,
theoretical time for the corresponding process can be
identified.
3.1 Introduction
When the number of factor increases, the quality of result is
also increase significantly. Also increase in factor relating
time will provide accurate information that can give
solutions to long term problems. Based on the company’s
structure and finance, application and maintenance of
fundamentals can be varied and their results may also be
deviated. At the end, results can be reliable by company,
once they carried out all other steps with great care and
interest.
The most important thing to focus is to substitute values in
their appropriate units because small error in their units can
leads to wrong value in overall calculation and also in
process view. So it is important to apply corresponding units
for values associated with it.
In general, the factors in the formula can be easily obtained
from the CNC machine and convert them to corresponding
units is the only work to do. For clear understanding, the
factors along with their units are listed below
© 2019, IRJET
|
Impact Factor value: 7.211
Let us consider that a Gear manufacturing company is
implementing the technique and will study the effect of
technique over the company’s performance. Jelena R.
Jovanovic et al [2] have discussed about several factors for
|
ISO 9001:2008 Certified Journal
|
Page 78
International Research Journal of Engineering and Technology (IRJET)
e-ISSN: 2395-0056
Volume: 06 Issue: 03 | Mar 2019
p-ISSN: 2395-0072
www.irjet.net
manufacturing time duration on basis of their paper the
table is made and the data collection is done.
3.4 Various time factors comparison
It is essential to understand all types of strategies that are
helpful to us. By studying the techniques and strategies, we
can able to select the one which is apt for our need and apply
them. So in terms of application, both of them has specific
advantages of their own but for time management
application, it is wise to choose one that manages time as
primary source.
3.2 Result with standard data collection method
In this method, general procedures are followed in order to
calculate the overall or general parameter which is “Total
time “in this case. Also through this method only the value
or number of parameter can be identified not the cause. This
may lead to poor understanding of process, may be ended up
in poor decision too. To understand both the concepts, let us
consider a real world examples of batch products with all
necessary parameters. At first, we can see an example for the
standard data collection method for gear manufacturing
company as per our assumption.
In order to provide broad over view, selection of technique
always depend on process and parameter that need to be
monitored. Once the types of techniques were shortlisted, it
is manager’s work to choose the best suitable one for the
application into the working system. As for as our example,
list of advantages that make the suggested method stood
ahead are as follows,
Table 3.2 Report of batch product using standard data
collection method
OD
110
106
140
169
158
130.8
Cutting
speed
40
80
35
40
35
50
Feed rate
0.6
0.6
0.75
0.75
0.6
0.75
Hob
travel
129.4
127.65
352
158
215
155.2
Total time
(hrs)
3.4
0.8
2.6
3.7
1.9
3.4
3.3 Result with customized data collection method
In this method, additional information collected from both
supplier and machine itself, should be processed and has to
be categorized based up on their groups. By sorting them
into groups, it is easy for processing the data. The results are
quite promising than the standard data collection method.
From this type of analyzing, you can see the deviance in the
time respective between real time and theoretical time.
Figure 3.4 Comparison between standard and
customized data collection
4. CONCLUSIONS
In order to visualize the effect of time factor in the
production management, example was given with
comparison between standard or present method and
advanced or prescribed method with same set of data. Let us
see the detailed report using our suggested data collection
methods for the gear manufacturing company as we
discussed earlier in this chapter
Time management is the most potential part in development
stage of an organisation as laid the foundation of successive
firms and organisation. It is very useful and prominently
used in many type of industries like manufacturing,
automation, etc. As the task of collecting data, interpolating
with required fields and analysis it for further study or usage
is general for all types of firms.
Table 3.2 Report of batch product using Advance data
collection method
OD
110
106
140
169
158
130.8
Cutting
speed
40
80
35
40
35
50
© 2019, IRJET
Feed
rate
0.6
0.6
0.75
0.75
0.6
0.75
|
Hob
travel
129.4
127.65
352
158
215
155.2
In specific, it will help in analysis and study of time
management in new process, detailed study of ongoing
process, collect report of customizable parameters for
specific areas of focus. Since industrial revolution made it
possible through lots of new proposal and rules to monitor.
In fact it also offer industrialists to learn and know about
new concepts and prototype so that they can make new
development over the others.
Theoretical
time (hrs)
1.59
0.66
1.92
1.60
1.50
1.33
Impact Factor value: 7.211
|
ISO 9001:2008 Certified Journal
|
Page 79
International Research Journal of Engineering and Technology (IRJET)
e-ISSN: 2395-0056
Volume: 06 Issue: 03 | Mar 2019
p-ISSN: 2395-0072
www.irjet.net
There is also other literatures that share the benefits of
method in whole another perspective view. Also, there are
other methods that contribute more to firms which will
eventually consume lots of time, manpower, and knowledge
to procure best results compared to others.
5. SCOPE FOR FUTURE WORK
This paper mainly focused on time monitoring
behaviour of process, there are also other problems
like inventory maintenance, proper machine
utilization, etc.
In this work, only specific approach method has
been discussed so that in future other methods
related to eliminate same problem can be
addressed.
In this work, time management is focused by using factors,
formula and concepts. In future number of factors affecting
can be increased based on the situation of application of
method.
REFERENCES
1.
S.V.Shewale,
S.R.Suryawanshi,
productivity
improvement of gear hobbing process by analyzing
process
parameters,
2016-Conferences
proceedings, International Journal of Engineering
Research & Technology, ISSN: 2278-0181.
2.
Elena R. Jovanovic, Dragan D. Milanovic, Radica D.
Duke, Manufacturing Cycle Time Analysis and
Scheduling to Optimize Its Duration, Journal of
Mechanical Engineering 60(2014)7-8,512-524,
D0I:10.5545/sv-jme.2013.1523
3.
Robert Endoy, “Estimating hobbing times”, Journal
of Gear Technology, 1989.
© 2019, IRJET
|
Impact Factor value: 7.211
|
ISO 9001:2008 Certified Journal
|
Page 80